RKC PCT-300 Instruction Manual

A

Resin Pressure Measuring System
Instruction Manual

CZ-100P (Resin Pressure Sensor)
PCT-300 (Output Converter)

IM100CZ04-E2

Thank you for purchasing this RKC product. In order to achieve
maximum performance and ensure proper operation of your new
instrument, carefully read all the instructions in this manual. Please
place this manual in a convenient location for easy reference.

CONTENTS

1. OUTLINE ······································································ 2

2. PRODUCT CHECK······················································· 2

3. HANDLING OF THE PRESSURE SENSOR ················ 2

4. WIRING ········································································ 4

5. ADJUSTMENT······························································ 5

6. LINEARIZING FUNCTION SETTING ··························· 6

7. TROUBLES AND CAUSE············································· 6

8. EXPLANATION OF EACH TERMS ······························ 7

9. SPECIFICATIONS························································ 7

SYMBOLS

WARNING

CAUTION

 An external protection device must be installed if failure

of this instrument could result in damage to the
instrument, equipment or injury to personnel.

 All wiring must be completed before power is turned on

to prevent electric shock, fire or damage to instrument
and equipment.

 This instrument must be used in accordance with the

specifications to prevent fire or damage to instrument
and equipment.

 This instrument is not intended for use in locations

subject to flammable or explosive gases.

 Do not touch high-voltage connections such as power

supply terminals, etc. to avoid electric shock.

 RKC is not responsible if this instrument is repaired,

modified or disassembled by other than
factory-approved personnel. Malfunction can occur and
warranty is void under these conditions.

: This mark indicates precautions that must be taken

if there is danger of electric shock, fire, etc., which
could result in loss of life or injury.

: This mark indicates that if these precautions and

operating procedures are not taken, damage to the
instrument may result.

: This mark indicates that all precautions should be

!

taken for safe usage.

: This mark indicates important information on

installation, handling and operating procedures.

: This mark indicates supplemental information on

installation, handling and operating procedures.

: This mark indicates where additional information

may be located.

!

 This is a Class A instrument. In a domestic environment, this

instrument may cause radio interference, in which case the user
may be required to take adequate measures.

 This instrument is protected from electric shock by reinforced

insulation. Provide reinforced insulation between the wire for the
input signal and the wires for instrument power supply, source of
power and loads.

 Be sure to provide an appropriate surge control circuit respectively

for the following:

- If input/output or signal lines within the building are longer than
30 meters.

- If input/output or signal lines leave the building, regardless the
length.

 This instrument is designed for installation in an enclosed

instrumentation panel. All high-voltage connections such as power
supply terminals must be enclosed in the instrumentation panel to
avoid electric shock by operating personnel.

 All precautions described in this manual should be taken to avoid

damage to the instrument or equipment.

 All wiring must be in accordance with local codes and regulations.
 To prevent instrument damage of failure, protect the power line

and the input/output lines from high currents with a protection
device such as fuse, circuit breaker, etc.

 For an instrument with 24 V power supply, supply power from a

SELV circuit.

 Prevent metal fragments or lead wire scraps from falling inside

instrument case to avoid electric shock, fire or malfunction.

 Tighten each terminal screw to the specified torque found in the

manual to avoid electric shock, fire or malfunction.

 Do not connect wires to unused terminals as this will interfere with

proper operation of the instrument.

 Turn off the power supply before cleaning the instrument.
 The resin adhered to this instrument should be cleaned to dry

cloth with a clean while the resin is still hardened, be careful of
burns.

 Tools such as wire wheels or abrasive cloths should never be

used to clean the process diaphragm.

 Do not apply impact to nor drop this product. If so, its damage or

fault may result.

 As precise parts are incorporated, do not give any shock and

handle carefully during transportation and installation. Take great
care not to scratch the diaphragm.

 Do not wipe or rub the nameplate on the outer case of the resin

pressure sensor with a cloth moistened with an organic solvent, or
a glove. If so, the printed section may be erased.



This product uses stainless steel, aluminum, and fluororesin (O-rings
and leadwire covering materials). When disposing of each part used
for this product, always follows the procedure for disposing of
industrial wastes stipulated by the respective local community.

CAUTION

NOTICE

 This manual assumes that the reader has a fundamental

knowledge of the principles of electricity, process control,
computer technology and communications.

 The figures, diagrams and numeric values used in this manual are

only for purpose of illustration.

 RKC is not responsible for any damage or injury that is caused as

a result of using this instrument, instrument failure or indirect
damage.

 Periodic maintenance is required for safe and proper operation of

this instrument. Some components have a limited service life, or
characteristics that change over time.

 Every effort has been made to ensure accuracy of all information

contained herein. RKC makes no warranty expressed or implied,
with respect to the accuracy of the information. The information in
this manual is subject to change without prior notice.

 No portion of this document may be reprinted, modified, copied,

transmitted, digitized, stored, processed or retrieved through any
mechanical, electronic, optical or other means without prior written
approval from RKC.

ll Rights Reserved, Copyright  1995, RKC INSTRUMENT INC.

RKC INSTRUMENT INC.

®

A

1. OUTLINE

1.1 Principle of Operation

When pressure is applied to a diaphragm in the resin pressure
sensor (CZ-100P), force acts upon a pressure sensing element
through a metal rod located near the diaphragm.
The pressure sensing element
used in CZ-100P has 4 gauges
adhered to a metallic elastic
body and connected to
Wheatstone bridge. Each strain
gauge made of metal
resistance foil with small
temperature coefficient slightly
changes its gauge resistance
due to strain occurring by the
application of force to the
elastic body. In this case,
as shown in the attached diagram (Fig. 1), the elastic body is in such
construction that by the application of force stretching strain occurs
in R1 and R3, while shrinking strain in R2 and R4 to increase the
gauge resistances of R1 and R3 and to decrease those of R2 and
R4. These resistance changes are detected as bridge voltage
change to generate the output proportional to the force applied. The
output thus generated is input to the PCT-300 output converter
which can finally output the DC voltages of 0 to 10 V, 0 to 10 mV, 1
to 5 V and 4 to 20 mA from its output terminals via a 3-stage
amplifier circuit.

1.2 Features

• The detection of strain caused by the deformation of an elastic
metal body within its elasticity limit using the highly reliable strain
gauge enables highly accurate pressure measurement.

• The dual construction of connecting pipe and pressure sensing
element portions extremely lessens output indication change
caused by external transient temperature change.

• Calibration normally performed to a strain gauge sensor becomes
easy and accurate without monitoring the output due to the
employment of the PCT-300 output converter.

4-core shielded cable

Fig. 2 Block diagram of resin pressure system

Output converter

PCT-300

CZ-100P

Pressure sensor

R4

R1 R2

+ −

pplied voltage

0 to 10 V
0 to 10 mV
1 to 5 V
4 to 20 mA

R3

Fig. 1

Indicator

Recorder

+

Signal (output)
voltage

−

Pressure
controller

(2) Diaphragm section material

S: SUS630 (Standard)
H: HASTELLOY C (Optional)

(3) Diaphragm surface treatment

N: Standard
K: CERAMIC Kanigin plate (Optional)

(4) Intrinsically safe

N: Standard (For non-explosionproof specification type)
G: Explosionproof specification type (For indoor use)
H: Explosionproof specification type (For outdoor use)

 Accessories

• Instruction Manual [IM100CZ04-E2]

• Copper Packing

(Included in only the Loose nut type [thickness: t = 2 mm])

If any of the products are missing, damaged, or if your
manual is incomplete, please contact RKC sales office or the
agent.

 Output converter

PCT-300 - 

(1) Intrinsically safe

N: Standard type (Non-explosionproof construction)
E: Intrinsically safe explosionproof construction pass type

(2) Number of outputs

2: For two output points (0 to 10 V DC, 0 to 10 mV DC)
3: For three output points
(0 to 10 V DC, 0 to 10 mV DC, 1 to 5 V DC)
4: For four output points
(0 to 10 V DC, 0 to 10 mV DC, 1 to 5 V DC, 4 to 20 mA DC)

(3) Optional function

N: None
G: Add gain selector switch
L: Add linearizing function
(Linearity error for using this product with the CZ-100P
becomes within ±0.5 % of span)

 Sensor connection cable (Sold separately)
W-AB-N*-PA-5000: Standard (For non−intrinsic safety)
[Cable length: 5 m]
W-AB-Y*-PB-5000: Intrinsically safety (Hazardous side)
[Cable length: 5 m]
W-AB-N*-BA-1000: Non−intrinsic safety (Non−hazardous side)
[Cable length: 1 m]

*: Cable cover type
(G: Heat−resistant glass coated cable, V: Vinyl coated cable, S: Silicon coated cable)

(1) (2) (3)

2. PRODUCT CHECK

Before using this product, check each of the following:

• Model code

• Check that all of the items delivered are complete.

• Check that there are no scratch or breakage in external

appearance.

 Resin pressure sensor

CZ-100P-

(1) Specification type

HB: Fixed nut type Standard PF3/8 L = 150
HC: Fixed nut type Standard PF3/8 L = 180
HZ: Fixed nut type Nonstandard size PF3/8
HL: Loose nut type Standard PF3/4 (20 to 100 MPa)
HLZ: Loose nut type Nonstandard size PF3/4 (20 to 100 MPa)
LL: Loose nut type Standard PF3/4 (5 to 10 MPa)
LLZ: Loose nut type Nonstandard size PF3/4 (5 to 10 MPa)
LLA: Loose nut type Standard PF3/4 (0.5 to 1 MPa)

IM100CZ04-E2

2

-  

(1) (2) (3) (4)

3. HANDLING OF THE PRESSURE
SENSOR

3.1 Caution in Mounting Pressure Sensors

 Mounting environment

• Ensure that no cooling pipes directly contact the pressure sensor
or connector, since the pressure reading accuracy may be affected
or the connector may be damaged.

• Do not locate any heat source near the pressure sensor or directly
expose it to heat. Otherwise, high-temperature deterioration of the
sensor block may occur. If the temperature could rise in the strain
gauge block located within the housing, cover possible heat
sources with insulation materials.

p

pip

y

A

A

A

• Do not use the pressure sensor under any of the following
environmental conditions:

- Where the sensor is exposed directly to cold air, warm air or hot

air.

- Where temperature variations are large.

- Where the sensor is exposed to direct sunlight.

- Where the sensor is directly splashed with water or rain, or the

humidity is high.

• Do not bring magnetic devices such as magnetic relays, etc. near
the pressure indicator. Also, keep power lines from the resin
pressure sensor cable.

• If the pressure sensor is used for screen changer operation, it may
suffer an impact during screen changer operation, causing sensor
troubles. In such a case, carefully consider the position and
direction when installing the sensor.

 Mounting pressure sensors

• When the diaphragm at the end of CZ-100P and its surroundings

completely touch with its mounting hole, large indication error may
occur. In this case, temperature may exert a large influence
especially upon the zero point. Therefore, much attention should
be paid when a mounting hole is drilled.

Do not wind sealing tapes, etc. round this section

reventing oil or resin leakage.

for

Packing surface (Sealing surface)
[Flat tightening or tapered tightening surface]
(Oil or resin leakage is prevented at this point.)

• When using a lead pipe cover (option), pay attention that the lead

pipe cover end does not directly touch the barrel. (See the “
Exposed length at the bottom of the sensor outer case”)

Barrel

Lead

e cover (option)

Mount the sensor so that this block
does not directl

touch the barrel.

• Prior to mounting the pressure sensor, check the appearance of

the diaphragm. If the diaphragm has a deformed or abnormal end,
it needs to be repaired or re-calibrated. As there is a case where
the diaphragm is already deformed by the application of overload
when used previously, carefully check its condition before the
pressure sensor is re-used.

 Mounting hole

• When mounting the pressure sensor, check its mounting hole

dimensions. (Do not overtighten its screw.)

• If resin or its carbide still remains in the mounting hole, this may

damage the pressure sensor. Therefore, prior to mounting the
sensor, always remove any residue from the mounting hole.

• Check that the diaphragm surface does not protrude from the

inner wall of the barrel, since this may score the diaphragm
surface with the screw, etc. If necessary, adjust the position
between the diaphragm surface and the inner wall of the barrel
using stainless steel packings, etc.

• For the loose nut type, resin leakage may occur more easily than

the fixed nut type, as the pressure sealing surface becomes wider.

If any resin leaks through the mounting gap of the sensor, use

copper packings (thickness: t = 2 mm) or aluminum packings

(thickness: t = 2 mm) by taking into account the position between

the diaphragm surface and the inner wall of the barrel. (Copper

Packing: Included in only the Loose nut type)

IM100CZ04-E2

 Mounting direction

• If the sensor is installed in the upright direction (Fig.1-A), it may be
affected directly by heat flow from heater or heat source (rising
current of heated air). In such a case, the temperature of the strain
gauge in the sensor may exceed an allowable maximum
temperature of 150 °C. In order not to exceed this limit
temperature, it is necessary to keep the sensor outer cylinder
surface at a temperature of less than 134 °C (Fig.2). Conduct the
following treatments.

1. In order to avoid heat flow, wind a heat insulating material round

such a heat source (heater, etc.).

2. Further extend the length of the exposed lead pipe.

• In order to keep the specified sensor performance longer, it is
recommended that the sensor outer cylinder surface temperature
be keep at less than 134 °C.

• When the sensor is installed in the upright position, thermal effects
on the sensor may not sufficiently lessen even if the length of the
exposed lead pipe is further extended. In this case, take measures
of 1.

• The effect of heat flow lessens as the installing direction of the
sensor changes from the slanting direction (Fig.1-B) to the
horizontal direction (Fig.1-C) in this order. In this case, take
measures of 1 and 2 if necessary by checking the sensor outer
cylinder surface temperature. (To the relevant manufacturer: It is
recommended that the sensor be installed in the horizontal or
slanting direction in order to lessen the effect of heat on the strain
gauge.)

B

C

: Upper mounting
B: Oblique mounting
C: Side mounting

A section of a extruder

(Figure 1)

Exposed length at the bottom of the sensor



outer case

• Cases where the temperature of the strain gauge in the sensor
become less than 150 °C is as follows:

− The effect of heat flow is small.

− The sensor is installed in the upright position.

− The diaphragm is at a temperature of 400 °C.

− The length of the exposed sensor outer cylinder is more than 70

mm. (Refer to Fig. at the right)

However, as the effect of heat flow from an actual extruder is
serious, if there is no enough exposed section below the sensor
outer cylinder even at a diaphragm temperature of less than 200
°C, the operating temperature of the sensor strain gauge may
exceed its limit. Therefore, check the temperature environment
where the sensor is installed (by indirectly checking the
temperature of the sensor outer cylinder surface), and take
necessary measures to lessen the temperature of the sensor
strain gauge by using a heat insulating material, if necessary.

If the temperature of the sensor outer cylinder surface
exceeds 160 °C, the outer cylinder surface changes its
color from black to dark brown and then brown in this
order. If it exceeds 180 °C, the color may change to silver.

Mounting environment:

mbient temperatures

at room temperatures

25 °C

Mounting adapter

Temperature of heater

CZ-100P

60

70

φ90

400 °C

The aims of a
temperature
measurement
position

(Figure 2)

3